US20110023811A1 - Piston for a two-stroke locomotive diesel engine having an egr system - Google Patents

Piston for a two-stroke locomotive diesel engine having an egr system Download PDF

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Publication number
US20110023811A1
US20110023811A1 US12/848,479 US84847910A US2011023811A1 US 20110023811 A1 US20110023811 A1 US 20110023811A1 US 84847910 A US84847910 A US 84847910A US 2011023811 A1 US2011023811 A1 US 2011023811A1
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United States
Prior art keywords
inches
piston bowl
piston
exhaust gas
engine
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Abandoned
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US12/848,479
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English (en)
Inventor
James W. Heilenbach
Frank M. Grazyk
Kenneth M. Sinko
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Progress Rail Locomotive Inc
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Electro Motive Diesel Inc
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Filing date
Publication date
Application filed by Electro Motive Diesel Inc filed Critical Electro Motive Diesel Inc
Priority to GB1201318.1A priority Critical patent/GB2485497A/en
Priority to US12/848,479 priority patent/US20110023811A1/en
Priority to PCT/US2010/044096 priority patent/WO2011017254A1/en
Priority to CN2010800408186A priority patent/CN102498279A/zh
Assigned to ELECTRO-MOTIVE DIESEL, INC. reassignment ELECTRO-MOTIVE DIESEL, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: GRACZK, FRANK M., HEILENBACH, JAMES W., SINKO, KENNETH M.
Publication of US20110023811A1 publication Critical patent/US20110023811A1/en
Abandoned legal-status Critical Current

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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02F—CYLINDERS, PISTONS OR CASINGS, FOR COMBUSTION ENGINES; ARRANGEMENTS OF SEALINGS IN COMBUSTION ENGINES
    • F02F3/00—Pistons 
    • F02F3/26—Pistons  having combustion chamber in piston head
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02B—INTERNAL-COMBUSTION PISTON ENGINES; COMBUSTION ENGINES IN GENERAL
    • F02B23/00—Other engines characterised by special shape or construction of combustion chambers to improve operation
    • F02B23/02—Other engines characterised by special shape or construction of combustion chambers to improve operation with compression ignition
    • F02B23/06—Other engines characterised by special shape or construction of combustion chambers to improve operation with compression ignition the combustion space being arranged in working piston
    • F02B23/0696—W-piston bowl, i.e. the combustion space having a central projection pointing towards the cylinder head and the surrounding wall being inclined towards the cylinder wall
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02B—INTERNAL-COMBUSTION PISTON ENGINES; COMBUSTION ENGINES IN GENERAL
    • F02B25/00—Engines characterised by using fresh charge for scavenging cylinders
    • F02B25/14—Engines characterised by using fresh charge for scavenging cylinders using reverse-flow scavenging, e.g. with both outlet and inlet ports arranged near bottom of piston stroke
    • F02B25/145—Engines characterised by using fresh charge for scavenging cylinders using reverse-flow scavenging, e.g. with both outlet and inlet ports arranged near bottom of piston stroke with intake and exhaust valves exclusively in the cylinder head
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02B—INTERNAL-COMBUSTION PISTON ENGINES; COMBUSTION ENGINES IN GENERAL
    • F02B47/00—Methods of operating engines involving adding non-fuel substances or anti-knock agents to combustion air, fuel, or fuel-air mixtures of engines
    • F02B47/04—Methods of operating engines involving adding non-fuel substances or anti-knock agents to combustion air, fuel, or fuel-air mixtures of engines the substances being other than water or steam only
    • F02B47/08—Methods of operating engines involving adding non-fuel substances or anti-knock agents to combustion air, fuel, or fuel-air mixtures of engines the substances being other than water or steam only the substances including exhaust gas
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/10—Internal combustion engine [ICE] based vehicles
    • Y02T10/12—Improving ICE efficiencies

Definitions

  • This invention relates to a locomotive diesel engine and, more particularly, to a piston with a unique bowl geometry for a two-stroke locomotive diesel engine having an exhaust gas recirculation system.
  • the present invention generally relates to a locomotive diesel engine and, more particularly, to a piston with a unique bowl geometry for optimizing a two-stroke locomotive diesel engine having an exhaust gas recirculation (“EGR”) system.
  • EGR exhaust gas recirculation
  • This piston achieves a reduced level of smoke and particulate matter; promotes the mixing process in the engine cylinder; and provides a lower compression ratio for reducing NO x emissions.
  • FIG. 1 illustrates a locomotive 100 including a uniflow two-stroke diesel engine system 200 .
  • the locomotive diesel engine system 200 generally includes an air system having a turbocharger 300 having a compressor 302 and a turbine 304 which provides compressed air to an engine 306 having an airbox 308 , power assemblies 310 , an exhaust manifold 312 , and a crankcase 314 .
  • the turbocharger 300 increases the power density of the engine 306 by compressing and increasing the amount of air transferred to the engine 306 .
  • the turbocharger 300 draws air from the atmosphere 316 , which is filtered using a conventional air filter 318 .
  • the filtered air is compressed by a compressor 302 .
  • the compressor 302 is powered by a turbine 304 , as will be discussed in further detail below.
  • a larger portion of the compressed air (or charge air) is transferred to an aftercooler 320 (or otherwise referred to as a heat exchanger, charge air cooler, or intercooler) where the charge air is cooled to a select temperature.
  • Another smaller portion of the charge air is transferred to a crankcase ventilation oil separator 322 which evacuates the crankcase 314 ; entrains crankcase gas; and filters entrained crankcase oil before releasing the mixture of crankcase gas and compressed air into the atmosphere 316 .
  • the cooled charge air from the aftercooler 320 enters the engine 306 via an airbox 308 .
  • the decrease in charge air intake temperature provides a denser intake charge to the engine which reduces NO X emissions while improving fuel economy.
  • the airbox 308 is a single enclosure which distributes the cooled charge air via intake ports to a plurality of cylinders (e.g., 324 ).
  • Each of the cylinders (e.g., 324 ) are closed by cylinder heads (e.g., 326 ).
  • Fuel injectors (not shown) in the cylinder heads (e.g., 326 ) introduce fuel into each of the cylinders (e.g., 324 ), where the fuel is mixed and combusted with the cooled charge air.
  • Each cylinder (e.g., 324 ) includes a piston (e.g., 328 ) which transfers the resultant force from combustion to the crankshaft 330 via a connecting rod (e.g., 332 ).
  • the piston (e.g., 328 ) includes a piston bowl, which facilitates mixture of fuel and trapped gas (including cooled charge air) necessary for combustion.
  • the cylinder heads (e.g., 326 ) include exhaust ports controlled by exhaust valves (e.g., 334 ) mounted in the cylinder heads (e.g., 326 ), which regulate the amount of exhaust gases expelled from the cylinders (e.g., 324 ) after combustion.
  • the combustion cycle of a diesel engine includes what is referred to as the scavenging process.
  • a positive pressure gradient is maintained from the intake port of the airbox 308 to the exhaust manifold 312 such that the cooled charge air from the airbox 308 charges the cylinders (e.g., 324 ) and scavenges most of the combusted gas from the previous combustion cycle.
  • the cooled charge air enters one end of the cylinder (e.g., 324 ) controlled by an associated piston (e.g., 328 ) and intake ports.
  • the cooled charge air mixes with the small amount of combusted gas remaining from the previous cycle.
  • the larger amount of combusted gas exits the other end of the cylinder (e.g., 324 ) via four exhaust valves (e.g., 334 ) and enters the exhaust manifold 312 as exhaust gas.
  • the control of these scavenging and mixing processes is instrumental in emissions reduction as well as in achieving desired levels of fuel economy.
  • the exhaust gas flow from the engine 306 is used to power the turbine 304 of the turbocharger 300 , and thereby the compressor 302 of the turbocharger 300 .
  • the exhaust gases are released into the atmosphere 316 via an exhaust stack 336 or silencer.
  • Emissions reduction may be achieved by recirculating some of the exhaust gas back through the engine system.
  • Major constituents of exhaust gas that are recirculated include N 2 , CO 2 , and water vapor, which affect the combustion process through dilution and thermal effects.
  • the dilution effect is caused by the reduction in the concentration of oxygen in intake air, and the thermal effect is caused by increasing the specific heat capacity of the charge.
  • the exhaust gases released into the atmosphere by a diesel engine include particulates, nitrogen oxides (NO X ) and other pollutants. Legislation has been passed to reduce the amount of pollutants that may be released into the atmosphere. Traditional systems have been implemented which reduce these pollutants, but at the expense of fuel efficiency. Accordingly, it is an object of the present invention to provide a system which reduces the amount of pollutants released by the diesel engine while achieving desired fuel efficiency.
  • NO X nitrogen oxides
  • the present invention generally relates to a diesel engine and, more particularly, to a piston for a uniflow two-stroke locomotive diesel engine having an EGR system.
  • the piston has a unique bowl geometry which achieves a reduced level of smoke and particulate matter; promotes the mixing process in the engine cylinder; and provides a lower compression ratio for reducing NO x emissions.
  • a piston bowl geometry arrangement for a diesel engine having an exhaust gas recirculation (EGR) system adapted to reduce NO X emissions and achieve desired fuel economy by recirculating exhaust gas through the engine.
  • the piston bowl geometry arrangement includes a toroidal major diameter between about 4.795 inches to about 5.045 inches; a toroidal minor radius between about 0.595 inches to about 0.665 inches; a toroidal submersion below the squish land between about 0.787 inches to about 0.867 inches; a center cone angle between about 26 degrees to about 34 degrees; a crown rim radius of about 0.375 inches; a crown thickness between about 0.196 inches to about 0.240 inches; a center spherical radius of about 0.79 inches; a piston diameter of about 8.50 inches; a piston bowl depth between about 1.647 inches to about 1.707 inches; and a piston bowl volume of about 0.305 cubic inches, wherein the piston bowl geometry arrangement promotes mixture of fuel and gas including recirculated exhaust gas in its volume and wherein the piston bowl volume of about
  • FIG. 1 is a perspective view of a locomotive including a two-stroke diesel engine system.
  • FIG. 2 is a partial cross-sectional perspective view of the two-stroke diesel engine system of FIG. 1 .
  • FIG. 3 is a system diagram of the two-stroke diesel engine of FIG. 2 having a conventional air system.
  • FIG. 4 is a system diagram of a two-stroke diesel engine having an EGR system.
  • FIG. 5A is a cross-sectional view of the two-stroke diesel engine of FIG. 4 .
  • FIG. 5B is a schematic, partly cut-away cross-sectional view of the two-stroke internal combustion diesel engine of FIG. 4 , showing the exhaust valves.
  • FIG. 5C is a schematic, partly cut-away cross-sectional view of a two-stroke internal combustion diesel engine of FIG. 4 , showing the fuel injector.
  • FIG. 6 is a partial side cross-sectional view of a piston according to the present invention.
  • FIG. 7A is a detail, partly cut-away sectional side view of a fuel injector nozzle according to the present invention.
  • FIG. 7B is a sectional view of a first preferred embodiment of the fuel injector nozzle of FIG. 7A .
  • FIG. 7C is a sectional view of a second preferred embodiment of the fuel injector nozzle of FIG. 7A .
  • FIG. 8A is a timing chart for the optimized two-stroke diesel engine, according to the present invention.
  • FIG. 8B is a graph showing the lift and velocity profiles of the exhaust for the entire engine cycle.
  • FIG. 8C is a cross-sectional view of an exhaust cam profile according to the present invention.
  • the present invention is directed to a piston for a uniflow two-stroke locomotive diesel engine having an EGR system.
  • the piston has a unique bowl geometry which achieves a reduced level of smoke and particulate matter; promotes the mixing process in the engine cylinder; and provides a lower compression ratio for reducing NO x emissions.
  • an EGR system 450 which recirculates through the engine 406 exhaust gases from the exhaust manifold 412 of the engine 406 , mixes the exhaust gases with the cooled charge air of the aftercooler 420 , and delivers such to the airbox 408 .
  • this EGR system only a select percentage of the exhaust gases is recirculated and mixed with the intake charge air in order to selectively reduce pollutant emissions (including NO X ) while achieving desired fuel efficiency.
  • the percentage of exhaust gases to be recirculated is also dependent on the amount of exhaust gas flow needed for powering the compressor 402 of the turbocharger 400 . It is desired that enough exhaust gas powers the turbine 404 of the turbocharger 400 such that an optimal amount of fresh air is transferred to the engine 406 for combustion purposes. For locomotive diesel engine applications, it is desired that less than about 35% of the total gas (including compressed fresh air from the turbocharger and recirculated exhaust gas) delivered to the airbox 408 be recirculated. This arrangement provides for pollutant emissions (including NO X ) to be reduced, while achieving desired fuel efficiency.
  • a flow regulating device may be provided for regulating the amount of exhaust gases to be recirculated.
  • the flow regulating device is a valve 452 as illustrated in FIG. 4 .
  • the flow regulating device may be a positive flow device 460 , wherein there is no valve (not shown) or the valve 452 may function as an on/off valve as will be discussed in greater detail below.
  • the select percentage of exhaust gases to be recirculated may be optionally filtered. Filtration is used to reduce the particulates that will be introduced into engine 406 during recirculation.
  • the introduction of particulates into the engine 406 causes accelerated wear especially in uniflow two-stroke diesel engine applications. If the exhaust gases are not filtered and recirculated into the engine, the unfiltered particulates from the combustion cycle would accelerate wear of engine components.
  • uniflow two-stroke diesel engines are especially sensitive to cylinder liner wall scuffing as hard particulates are dragged along the cylinder liner walls by piston rings after passing through the intake ports.
  • Oxidation and filtration may also be used to prevent fouling and wear of other EGR system components (e.g., cooler 458 and positive flow device 460 ) or engine system components.
  • a diesel oxidation catalyst (DOC) 454 and a diesel particulate filter (DPF) 456 are provided for filtration purposes.
  • the DOC 454 uses an oxidation process to reduce the particulate matter (PM), hydrocarbons and/or carbon monoxide emissions in the exhaust gases.
  • the DPF 456 includes a filter to reduce PM and/or soot from the exhaust gases.
  • the DOC/DPF arrangement may be adapted to passively regenerate and oxidize soot.
  • a DOC 454 and DPF 456 are shown, other comparable filters may be used.
  • the filtered exhaust gas is optionally cooled using cooler 458 .
  • the cooler 458 serves to decrease the recirculated exhaust gas temperature, thereby providing a denser intake charge to the engine.
  • the decrease in recirculated exhaust gas intake temperature reduces NO X emissions and improves fuel economy. It is preferable to have cooled exhaust gas as compared to hotter exhaust gas at this point in the EGR system due to ease of deliverability and compatibility with downstream EGR system and engine components.
  • the cooled exhaust gas flows to a positive flow device 460 which provides for the necessary pressure increase to overcome the pressure loss within the EGR system 450 itself and overcome the adverse pressure gradient between the exhaust manifold 412 and the introduction location of the recirculated exhaust gas.
  • the positive flow device 460 increases the static pressure of the recirculated exhaust gas sufficient to introduce the exhaust gas upstream of the power assembly 410 .
  • the positive flow device 460 decreases the static pressure upstream of the power assembly 410 at the introduction location sufficient to force a positive static pressure gradient between the exhaust manifold 412 and the introduction location upstream of the power assembly.
  • the positive flow device 460 may be in the form of a roots blower, a venturi, impeller, propeller, turbocharger, pump or the like.
  • the positive flow device 460 may be internally sealed such that oil does not contaminate the exhaust gas to be recirculated.
  • the airbox 408 e.g., about 94.39 inHga
  • the exhaust manifold 412 e.g., about 85.46 inHga
  • the recirculated exhaust gas pressure is increased to at least match the aftercooler discharge pressure as well as overcome additional pressure drops through the EGR system 450 .
  • the exhaust gas is compressed by the positive flow device 460 and mixed with fresh air from the aftercooler 420 in order to reduce NO X emissions while achieving desired fuel economy. It is preferable that the introduction of the exhaust gas is performed in a manner which promotes mixing of recirculated exhaust gas and fresh air.
  • a positive flow device 460 may instead be used to regulate the amount of exhaust gas to be recirculated.
  • the positive flow device 460 may be adapted to control the recirculation flow rate of exhaust gas air from the engine 406 , through the EGR system 450 , and back into the engine 406 .
  • the valve 452 may function as an on/off type valve, wherein the positive flow device 460 regulates the recirculation flow rate by adapting the circulation speed of the device. In this arrangement, by varying the speed of the positive flow device 460 , a varying amount of exhaust gas may be recirculated.
  • the positive flow device 460 is a positive displacement pump (e.g., a roots blower) which regulates the recirculation flow rate by adjusting its speed.
  • a new turbocharger 400 is provided having a higher pressure ratio than that of the prior art uniflow two-stroke diesel engine turbochargers.
  • the new turbocharger provides for a higher compressed charge of fresh air, which is mixed with the recirculated exhaust gas from the positive flow device 460 .
  • This high pressure mixture of fresh air and exhaust gas delivered to the engine 406 provides the desired trapped mass of oxygen necessary for combustion given the low oxygen concentration of the trapped mixture of fresh air and cooled exhaust gas.
  • the EGR system 450 of FIG. 4 is shown for illustrative purposes only. Other comparable EGR systems may be similarly implemented in order to recirculate exhaust gas in the engine for the purposes of reducing NO x emissions.
  • recirculated exhaust gas may be alternatively introduced upstream of the aftercooler and cooled thereby before being directed to the airbox of the engine.
  • the filtered exhaust gas may optionally be directed to the aftercooler without the addition of the cooler in the EGR system.
  • a control system may further be provided which controls the select components of the EGR system.
  • a control system controls the flow regulating device to adaptively regulate the amount of exhaust gas being recirculated based on various operating conditions of the locomotive.
  • FIGS. 5A-5C are various cross-sectional views of a uniflow two-stroke diesel engine being redesigned for use with the EGR system 450 of FIG. 4 .
  • the first new engine component redesigned for use with the EGR system is the piston.
  • a piston 583 is carried by a piston carrier.
  • the piston includes a generally annular sidewall having a plurality of grooves thereon.
  • the grooves 593 receive a plurality of rings to seal the piston 583 against the sidewall of the cylinder liner, as is well known in the art.
  • a connecting rod 595 may also be pivotally secured to the piston in a conventional manner.
  • a new piston bowl geometry when paired with the fuel injection system described below, promotes the mixture of fuel and the trapped gas (including intake charge air and recirculated exhaust gas) in the cylinder. Furthermore, the piston bowl helps to reduce the amount of smoke and particulate matter by its new unique geometry.
  • the piston bowl volume, cylinder, cylinder head and exhaust valves define the volume at piston top dead center (TDC) being preferably equal to about 0.3053 cubic inches, thereby defining the compression ratio which is about 17:1.
  • the lower compression ratio offsets the higher airbox pressure, thereby limiting maximum firing pressure and lowering NO X .
  • the piston bowl 683 includes a center portion having a generally spherical shape.
  • the center portion has a center spherical radius R c ( 620 ) preferably equal to about 0.79 inches.
  • a cone portion is connected to the center portion and preferably is formed at an angle (center cone angle A c ( 616 )) preferably equal to 30 degrees plus or minus 4 degrees.
  • An annular toroidal surface is formed adjacent to the cone portion and is defined in part by a toroidal major diameter D tm ( 610 ) preferably equal to 4.92 inches, plus or minus 0.125 inches, and a toroidal minor radius R tm ( 612 ) preferably equal to 0.63 inches, plus or minus 0.035 inches.
  • a crown rim is formed adjacent to the annular toroidal surface and is connected to an upper flat rim face of a sidewall.
  • the crown rim radius R cr ( 618 ) is preferably equal to about 0.375 inches.
  • the annular toroidal surface is preferably formed wherein the toroidal minor radius R tm ( 612 ) is measured from a point that is submerged 0.827 inches, plus or minus 0.04 inches, below the upper flat rim face. This is also known as the toroidal submersion below squish land and is denoted as T s ( 614 ) in FIG. 6 .
  • the new piston bowl 683 design includes the following: a toroidal major diameter D tm ( 610 ) preferably equal to 4.92 inches, plus or minus 0.125 inches; a toroidal minor radius R tm ( 612 ) preferably equal to 0.63 inches, plus or minus 0.035 inches; a toroidal submersion T s ( 614 ) below the squish land preferably equal to 0.827 inches, plus or minus 0.04 inches; a center cone angle A c ( 616 ) preferably equal to 30 degrees plus or minus 4 degrees; a crown rim radius R CR ( 618 ) preferably equal to 0.375 inches; a crown thickness preferably between about 0.196 inches and about 0.240 inches; a center spherical radius R c ( 620 ) preferably equal to 0.79 inches; a piston diameter D preferably equal to 8.50 inches; and a piston bowl depth B preferably equal to 1.677 inches, plus or minus 0.03 inches.
  • the ratio of the toroidal major diameter D tm ( 610 ) relative to the piston diameter D is 1:1.73; the ratio of the toroidal minor radius R tm ( 612 ) relative to the piston diameter D is 1:13.49; and the ratio of piston bowl depth B to the piston diameter D is 1:5.07.
  • the piston arrangement also has an increased squish volume (and piston bowl volume) of about 0.305 cubic inches. Additionally, the squish area is preferably about 2.827 square inches and the squish height is preferably about 0.108 inches. As a result of the increased squish volume, the engine compression ratio is lowered from about 18.4:1 to about 17:1. The lower compression ratio offsets the higher airbox pressure, thereby limiting maximum firing pressure and lowering NO X .
  • the redesigned piston is paired with a fuel injector system as shown at 587 in FIGS. 5A and 5C .
  • the fuel injector 787 has a fuel injector nozzle body 788 having six or seven, fuel injection holes 790 .
  • the fuel injection holes 790 are of mutually equal size and are equidistantly spaced concentrically around a nozzle centerline N.
  • Each of the fuel injector holes 790 is provided with a reduced diameter hole size, the hole diameter being within the range of between preferably 0.0133 inches and 0.0152 inches.
  • the included Angle A of the fuel injection holes is preferably 150 degrees, plus or minus 4 degrees.
  • the reduced diameter hole size provides reduction in the fuel injection rate along with an increase in fuel injection duration and a rise in peak fuel injection pressure, and serves to lower the NO X formation during the fuel combustion process, as it sprays fuel onto the new piston bowl geometry to lower smoke and particulate levels.
  • FIGS. 5A-5C illustrate the two cylinder banks 599 A, 599 B of the engine, each having a plurality of cylinders closed by cylinder heads 597 .
  • the cylinder heads 597 contain exhaust ports that communicate with the combustion chambers and are controlled by exhaust valves 553 mounted in the cylinder heads 597 .
  • the exhaust valves 553 regulate the amount of exhaust gases expelled from the combustion chamber.
  • the timing, lift and velocity of exhaust valve opening and closing are controlled in order to attain the desired NO x emission levels and the desired levels of cylinder scavenging and mixing.
  • the exhaust valves 553 are mechanically actuated by an exhaust cam 580 of a camshaft driving an associated valve actuating mechanism, such as a rocker arm 582 .
  • FIG. 5A illustrates a cross-sectional view of the two-stroke diesel engine, showing two exhaust valves 553 being actuated by an exhaust cam 580 .
  • the exhaust cam 580 generally includes a select shape which determines the lift, timing and velocity of exhaust valve actuation.
  • the exhaust cam 580 lobe engages a roller 584 located on a rocker arm 582 .
  • the rocker arm 582 engages a valve bridge 585 , which causes compression in adjacent springs and causes the exhaust valves 553 to open.
  • the exhaust cam 580 controls the timing, lift and velocity of exhaust valve opening and closing in order to attain the desired NO x emission levels and the desired levels of cylinder scavenging and mixing.
  • the engine timing chart of FIG. 8A illustrates the effects of the redesigned engine components on the EGR system.
  • combustion occurs at or near piston TDC.
  • Fuel injection into the cylinder begins near TDC and ends after TDC, with specific timing being dependent on the locomotive operating conditions. For example, at full load, the fuel injection timing starts at about 7 degrees before TDC and ends at about 13 degrees after TDC.
  • Expansion of the cylinder gas generally begins at TDC and continues until exhaust valves open. The exhaust valves open at about 79 degrees past TDC. Until about 108 degrees past TDC, the exhaust valves open at a slow constant velocity as will be described in further detail with regards to FIG.
  • exhaust gas exits the cylinder as the cylinder pressure is higher than the exhaust pressure.
  • the intake ports open at about 125 degrees past TDC at which point cylinder pressure is generally higher than airbox pressure.
  • the cylinder pressure causes most of the exhaust gas to flow through the exhaust valves while some exhaust gas may flow into the airbox.
  • a positive pressure gradient from the intake ports to the exhaust valves then charges the cylinder with cooled charge air (and recirculated exhaust gas) from the airbox and scavenges most of the exhaust gas from the previous cycle.
  • the cooled charge air (and recirculated exhaust gas) mixes with the small amount of exhaust gas remaining from the previous cycle.
  • the peak valve lift during the scavenging process occurs near bottom dead center at about 177 degrees past TDC, where compression begins. Cooled charge air (and recirculated exhaust gas) continues to enter the cylinder until the intake ports close at about 235 degrees past TDC. Exhaust gas and cooled charged air (and recirculated exhaust gas) are compressed and scavenging continues until about 261 degrees after TDC when exhaust valves close. It is important to note that the exhaust valves are nearly closed at about 248 degrees past TDC. Cylinder compression continues until TDC, near which the combustion cycle begins once again.
  • the geometry of the new piston bowl (shown in FIG. 6 ) and intake port promotes the mixture of fuel and the trapped gas (including cooled charge air and recirculated exhaust gas) in the cylinder.
  • the piston bowl volume, cylinder, cylinder head and exhaust valves define the volume at TDC, thereby defining the compression ratio which is about 16.7 to about 17.5.
  • the lower compression ratio offsets the higher airbox pressure, thereby limiting maximum firing pressure and lowering NO X .
  • valves are mechanically actuated by exhaust cams of a camshaft. Because the timing and lift of all exhaust valve events are determined by the cam, a new cam lobe arrangement for exhaust valves is provided to achieve external EGR in accordance with the new EGR system.
  • the timing and lift of valve actuation in part, depends on what portion of the cam (i.e. cam angle) is engaging the roller at a given point in time.
  • the timing and lift of valve opening and closing is important to attain the desired NO x emission levels and the desired levels of cylinder scavenging and mixing.
  • the exhaust profile of the cam has a peak roller lift when the cam rotates to about 177 degrees after TDC, as illustrated in FIGS. 8A-8C .
  • the valve closes as the cam rotates to about 261 degrees after TDC. Because the exhaust valve remains open for a longer period of time, as compared to the system of FIG. 3 , it provides for a longer period for cylinder scavenging.
  • FIGS. 8B and 8C further illustrate the correlation between cam angle and exhaust valve lift.
  • the steepness of the cam corresponds to the velocity of valve opening and closing.
  • the cam generally includes a base circle and a cam profile lobe. When the base circle engages the rocker arm roller, the valve is closed. Once the cam rotates such that the cam profile lobe, and specifically the ramp portion of the lobe, engages the roller, the exhaust valve begins to lift. Although the base circle is circular, the lobe is oblong. Therefore, as the angle and steepness of the portion of the cam engaging the rocker arm changes, the velocity of valve opening changes accordingly.
  • the exhaust valve begins to open when the cam rotates to an angle of 79 degrees (shown at 800 ).
  • the valve opens at a low constant velocity (shown between 800 and 810 ) for about 29 degrees, until the cam rotates to 108 degrees (shown at 810 ).
  • Maintaining a low constant velocity during valve opening and closing is an important factor in avoiding mechanical failure of the valve system.
  • the opening and closing ramps are designed such that the valve seating and valve unseating velocities are low. The lower the opening and/or closing velocity, the lower the valve seating and valve unseating loads are exerted on the valve train system.
  • the low constant velocity ends when the cam rotates to about 108 degrees, at which point the steep portion (or flank) of the cam lobe engages and lifts the roller.
  • valve opening velocity sharply increases (shown between 810 and 830 in FIG. 8B ) over 10 fold.
  • the valve opening velocity decreases.
  • the cam reaches a rotation of about 177 degrees (shown at 840 ) it causes the roller to reach its peak lift, which corresponds to the peak valve lift.
  • the nose of the cam lobe is engaging the roller and valve velocity returns to 0 in/degrees (shown at 850 ).
  • the valve begins to close initially at a higher velocity until it reaches about 248 degrees.
  • the valve is almost closed when the cam rotates to an angle of about 248 degrees (shown at 860 ), at which point the valve closing velocity slows to constant velocity (shown at 870 ).
  • This low constant velocity is maintained for approximately 13 degrees until the cam rotates, to an angle of about 261 degrees, at which point the valve is fully closed (shown at 890 ).
  • the various embodiments of the present invention may be applied to both low and high pressure loop EGR systems.
  • the various embodiments of the present invention may be applied to locomotive two-stroke diesel engines may be applied to engines having various numbers of cylinders (e.g., 8 cylinders, 12 cylinders, 16 cylinders, 18 cylinders, 20 cylinders, etc.).
  • the various embodiments may further be applied to other two-stroke uniflow scavenged diesel engine applications other than for locomotive applications (e.g., marine applications).
  • Embodiments of the present invention relate to a locomotive diesel engine and, more particularly, to a piston for a two-stroke locomotive diesel engine having an exhaust gas recirculation system.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Exhaust-Gas Circulating Devices (AREA)
  • Output Control And Ontrol Of Special Type Engine (AREA)
US12/848,479 2009-08-01 2010-08-02 Piston for a two-stroke locomotive diesel engine having an egr system Abandoned US20110023811A1 (en)

Priority Applications (4)

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GB1201318.1A GB2485497A (en) 2009-08-01 2010-08-02 Piston for a two-stroke locomotive diesel engine having an EGR system
US12/848,479 US20110023811A1 (en) 2009-08-01 2010-08-02 Piston for a two-stroke locomotive diesel engine having an egr system
PCT/US2010/044096 WO2011017254A1 (en) 2009-08-01 2010-08-02 Piston for a two-stroke locomotive diesel engine having an egr system
CN2010800408186A CN102498279A (zh) 2009-08-01 2010-08-02 用于具有egr系统的二冲程机车柴油机的活塞

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US23069809P 2009-08-01 2009-08-01
US12/848,479 US20110023811A1 (en) 2009-08-01 2010-08-02 Piston for a two-stroke locomotive diesel engine having an egr system

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US12/848,511 Abandoned US20110023854A1 (en) 2009-08-01 2010-08-02 Piston arrangement for a two-stroke locomotive diesel engine having an egr system
US12/848,479 Abandoned US20110023811A1 (en) 2009-08-01 2010-08-02 Piston for a two-stroke locomotive diesel engine having an egr system
US12/848,604 Abandoned US20110023844A1 (en) 2009-08-01 2010-08-02 Engine exhaust valve timing and lift system for a two-stroke locomotive diesel engine having an egr system

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US (3) US20110023854A1 (zh)
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US8683974B2 (en) 2011-08-29 2014-04-01 Electro-Motive Diesel, Inc. Piston
US9387567B2 (en) 2012-09-13 2016-07-12 Electro-Motive Diesel, Inc. Cylinder liner having three-tiered surface finish
AT524480A1 (de) * 2021-04-02 2022-04-15 Avl List Gmbh Verbrennungssystem und Brennkraftmaschine
AT525166A4 (de) * 2021-06-24 2023-01-15 Avl List Gmbh Verbrennungssystem für eine luftverdichtende brennkraftmaschine

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US9303597B2 (en) * 2012-06-22 2016-04-05 GM Global Technology Operations LLC Engine with dedicated EGR exhaust port and independent exhaust valve control
US9404427B2 (en) 2012-06-22 2016-08-02 GM Global Technology Operations LLC Engine with dedicated EGR exhaust port and independently deactivatable exhaust valves
US11078867B2 (en) 2013-04-16 2021-08-03 Delphi Technologies Ip Limited Piston and bowl for gasoline direct injection compression ignition (GDCI)
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US8683974B2 (en) 2011-08-29 2014-04-01 Electro-Motive Diesel, Inc. Piston
US9387567B2 (en) 2012-09-13 2016-07-12 Electro-Motive Diesel, Inc. Cylinder liner having three-tiered surface finish
AT524480A1 (de) * 2021-04-02 2022-04-15 Avl List Gmbh Verbrennungssystem und Brennkraftmaschine
AT525166A4 (de) * 2021-06-24 2023-01-15 Avl List Gmbh Verbrennungssystem für eine luftverdichtende brennkraftmaschine
AT525166B1 (de) * 2021-06-24 2023-01-15 Avl List Gmbh Verbrennungssystem für eine luftverdichtende brennkraftmaschine

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CN102498279A (zh) 2012-06-13
CN102498280A (zh) 2012-06-13
DE112010003158T5 (de) 2012-05-10
US20110023844A1 (en) 2011-02-03
WO2011017262A1 (en) 2011-02-10
WO2011017259A8 (en) 2011-09-29
US20110023854A1 (en) 2011-02-03
WO2011017254A1 (en) 2011-02-10

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